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HEIDENHAIN

DR.JOHANNES HEIDENHAN GmbH


D-8225 Traunreut Tel. (08669) 31-D
Kundendienst

..~

Service

Subject

to change (without

Manual

TNC~~lSl

notice)

DR. JOHANNES HEIDENHAIN GmbH is constantly


working on further
developments
of its TNC Controls.
It is therefore
possible
that details
of your Control may differ
slightly
from those
described herein.
If that is the case please order a suitably
revised
issue of the Service Manual.
Copying/Duplication
This manual is provided
subject to the condition
that no part
of it shall be reproduced in any form or by any means without
our prior consent in writing.
Issue:

01/87

lleIuelullnll\
DR. JDHANNES HEIDENHAJN GmbH
D-8225 Traunreut Tel. (08669) 31-O

SERVICE

Page

Kundendienst

contents

1.

Use nf
-1 tllc
-l

2.
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6

Fault

Diagnosis
for fault-finding
Flow diagrams
for fault
location
Fault
diagnosis
for the complete
installation
Use of the integrated
supervision
system
Testing
of the VDU and associated
circuitry
Testing
of the mains supply
and the Power Supply
Testing
of the measuring
systems
and wiring

3.
3.1
3.1.1
3.1.2
3.1.3
3.2
3.3
3.4

Exchange
Information
Exchanoina
Control
units
Procedure
for exchanging
the TNC 151 A/E Control
Procedure
for exchanging
the TNC 151 P/V Control
Procedure
for exchanging
the PIG I/O Board of the
Board Exchange
Software
Exchange
ReDlacement
Parts,
Loan/Exchange/Service
Units

4.
4.1
4.2
4.3
4.4

Additional
Information
Block Diagram
Description
Block
Diagram
TNC 151
Wiring
Diagrams
Machine
Parameters

Service

Manual

2
^

"
"
"
"
"
n
"
"
n
"
"
"
nn

3
4
4
5
14
15
17
18

..

procedure

Burn-In

Page
..

Unit

Test

PL 100 B/110

.l

'1
"

36
37
37
38
39
40
45
48

"
X8
n
"
"

50
50
55
70
75

MANUAL TNC 151

neluelunnllu
DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut .Tel. (08669) 31-O

1. Use of the Service Manual TNC 151


In order to determine the fault condition
on an NC machine,
a fundamental knowledge of the machine and the drives is
necessary, as well a a knowledge of their interaction
with
the Control and measuring system. In addition,
improper use
such as incorrect
NC programming or incorrect
of the Control,
selection
of machine parameters can lead to the occurrence
Further information
in this
respect can
of fault conditions.
be found in:
.TNC 151 OPERATING MANUAL
.TNC 151 MOUNTING INSTRUCTIONS AND INTERFACE CIRCUIT CONTROLMACHINE
.TNC 151 PLC-DESCRIPTION

SERVICE MANUAL TNC 151


Page 2
Section 1

The TNC 151 Service Manual is used for the diagnosis,


localisation
and remedying of faults on TNC controlled
machines.
In chapter 2, Fault Diagnosis,
a set of flowcharts
enables
the user to pinpoint
the source of a fault from its symptoms _
An integrated
built-in
supervision
system and a Burn-In
Test Program specifically
developed for testing the Control
can aid in the location
of faults.
Important
guidance for the exchange of entire Controls,
individual
boards, or software is given in section 3,
Exchange Information.
Section 4, Additional
Information,
contains a block diagram of the Control,
a wiring diagram for each version of
the Control,
and a list of machine parameters with permissible entry values.

HEIDENHAIN

SERVICE
Page 3
Section

DR. JOHANNES HElDENHAlN GmbH


D-8225 Traunreut .Tel. (08669) 31-O
Kundendienst
2.

Fault

2.1

procedure

Diagnosis
for

fault-finding

To locate
and rectify
a fault
that
has arisen
in a TNC installation,
it is of foremost
importance
to analyse
the behaviour
of the system
as a whole:
that
is,
the TNC Control,
the machine-tool
and the measuring
system.
in flow
diagram
form,
the procedure
for
exam2.2.1
shows,
ining
the complete
installation.
In addition,
the HEIDENHAIN
TNC 151 Contouring
Control
includes
an extensive
integrated
supervision
system
for the
avoidance
of entry/operator
faults
and for the recognition
and diagnosis
of technical
defects
in the installation
(see section
2.2.2)
The Burn-In
Test
Program
can be used as further
fault
localizing
and in the dynamic
testing
of
hardware
(see section
2.2.6).

support
in
the Control's

MANUAL
2/2.1

TNC 153

SERVICE
Page 4
Section
Kundendienst

2.2

Flow

diagrams

2.2.1

Fault
diagnosis
(Control/Measuring

for

fault
for

location

the complete
installation
System/Machine-tool)

MANUAL
2.2/2.2.1

TNC 151

neluelunnllu
DR. JOHANNES

D-8225Traunreut

2.2.2

Use

of

the

HElDENHAlN

.Tel. (08669)

integrated

GmbH

SERVICE
Page 5
Section

31-O

supervision

system

The TNC 151 incorporates


an extensive
integrated
supervision
system
for
the avoidance
of operator-errors
and the detection
and diagnosis
of technical
faults
in the TNC installation
(ie the installation
comprising
the TNC, the machine-tool
and the measuring
system).
The supervision
system
is made up
and software
within
the TNC, and
the TNC is switched
on. If a fault
a message
operator-error
occurs,
cating
(in abbreviated
form)
the

of a mixture
of hardware
operates
continuously
whilst
is detected,
or if an
will
be displayed,
indinature
of the problem.

Flashing
ASIS

fault
X/Y/Z/4

messages
MEAS.

EMERGENCY

Example
of fault
GROSS POSITIONING

on machine-tool:
ERROR A

SYSTEM DEFECTIVE

STOP PLC

TNC OPERATING

ERROR A/B/C/D

TEMP.

EXCEEDED

ERROR IN PLC PROGRAM A...Q


TNC ELECTRONICS

fault
with
measuring
SYSTEM DEFECTIVE

TNC 151

POINT

GROSS POSITIONING

example
of
X-MEASURING

2.2.2

STOP DEFECTIVE

WRONG REFERENCE

Example
of fault
with
TNC internal
electronics:
a) TNC OPERATING TEMP. EXCEEDED
b) EXCHANGE BUFFER BATTERY
c) TNC ELECTRONICS
DEFECTIVE
O...3/A...K

TNC 151

The system
distinguishes
between
what are considered
to be
harmless
errors
and serious
faults,
in that
faults
are shown
as flashing
displays.
Examples
of faults
are measuring
system
faults,
drive
faults
and faults
in the TNC's
internal
electronics.
The occurrence
of a fault
leads
to the machine
being
switched
off
via the emergency-stop
contactor.
The fault
must
then be rectified
before
the TNC is switched
on again.

EMERGENCY
Example
of operator-error:
a) KEY NON-FUNCTIONAL
b) ENTRY VALUE INCORRECT

MANUAL

DEFECTIVE

O...3/A...K

system:
CHECK SUM ERROR XXOO...XXFF

The significance
pages 8 to 13
A (non-flashing)
@key
on the
A list
of error

of

these

fault

messages

is

explained

on

error
message
can be cleared
by pressing
the
which
normal
operation
may resume.
TNC, after
messages
is given
on page 7.

HEIDENHAIN

SERVICE
Page 6
Section

DR. JOHANNES HEIDENHAN GmbH


D-8225 Traunreut.Tel.(08669)31-0

Error

message

"MCBA?JGB

MANUAL TNC 151


2.2.2

BUFFER

BATTBRY"

Particular
mention
should
also
be made about
the implications
of the instruction
to exchange
the buffer
battery:
If the dialogue
display
indicates
"EXCHANGE BUFFER BATTERY",
new batteries
must be inserted
within
one week.
The buffer
battery
compartment
is located
behind
the screw
cover
in the lower
left-hand
corner
of the operating
panel.
When exchanging
the batteries,
special
care
should
be taken
that
the polarity
is correct
(POS-pole
of battery
outwards).
The battery
needs to have IEC designation
"LR 6" and must be
of the leak-proof
type.
We especially
recommend
the use of
VARTA Alkaline
batteries
type
"4006".
With
discharged
(or
missing)
buffer
batteries,
the memory for the machine
parameters
and for the user-program
will
be supported
only
as long
as the mains
remains
switched
on. Continued
operation
is still
possible
but the memory contents
will
become erased
in the
event
of a mains
failure.
Please
note that
the TNC has to be
switched
on when exchanging
the buffer
batteries.
If a mains
failure
occurs
during
a battery.chanqe
(or when the battery
is
discharged
or missing),
the re-entry
of the machine
parameters
and the user-program
will
be necessary.

Use

of

the

integrated

supervision

system.

HEIDENHAIN

SERVICE
Page 7
Section

DR. JOHANNES HEIDENHAIN GmbH


D-8225 Traunreut
Tel. (08669) 31-O

MANUAL TNC 151


2.2.2

Kundendienst

Error
The
(i)
(ii)

messaqes

TNC 151

meanings
of many of these
error
messages
are
Operating
Manual
TNC 155 A/TNC 155 P
Mounting
Instructions
and Interface
Circuit

FEY NON-FUNCTIONAL
PROGRAM MEMORY EXCEEDED
SEARCH ADDRESS MISSING
TOOL DEF 0 NOT PERMI'M'ED
PROGRAM NUMBER ON TAPE ALLOCATED
JUMP TO LABEL 0 NOT PERMITTED
ENTRY VALUF INCORRECT
CC-BLOCK
MISSING
CIRCLE
END POS. INCORRECT
TOOL DEF MISSING
TOOL CALL MISSING
LABEL NUMBER NGT ALLOCATED
EXCESSIVE
SUPROGRAMMING
ANGLE REFERENCE MISSING
PLANE WRONGLY DEFINED
TOOLRADIUS
TOOLARGE
ROUNDING RADIUS TOO LARGE
PATH OFFSET WRONGLY STARTED
PATH OFFSET WRONGLY ENDED
ROUNDING-OFF
UNDFINBD
ROUNDING-OFF
NOT PERMITTED
AXIS DOUBLE PROGRAMMED
WRONG RPM
NO EDITING
OF RUNNING PGM
RADIUS COMP. UNDEFINED
LIMIT
SWITCH X+
LIMIT
SWITCH XLIMIT
SWITCH Y+
LIMIT
SWITCH Y-

explained

in:

Control-Machine

TNC 151 A/TNC

LIMIT
SWITCH AXIS Z+
LIMIT
SWITCH AXIS ZLIMIT
SWITCH AXIS
4+
LIMIT
SWITCH AXIS 4EXCHANGE BUFFER BATTERY
TRANSFERRED DATA INCORRECT
ME: CASSETTE MISSING
ME: CASSETTE LOCKED
NE: WRONG MODE SELECTED
NE: WRONG PROGRAM DATA
MB: CASSETTE EMPTY
ME: PROGRAM INCOMPLETE
ME: TAPE END
WRONG PROGRAM DATA
MACHINE PARAMETER INCOMPLETE
EXT. IN-/OUTPUT
NOT READY
MIRROR IMAGE ON TOOL AXIS
WRONG AXIS PRCGRANMED
NRONG SIGN PRCGRANMED
SPINDEL ROTATES MISSING
SLOT WIDTH TOO LARGE
CYCLE INCOMPLETE
SELECTED BLOCK NOT ADDRESSED
PROGRAM START UNDEFINED
POSITIONING
ERROR
EMERGENCY STOP
ARITHMETICAL
ERROR
OPERATION PARAMETERS ERASED
3D-INTERPOLATION
NOT PERMITTED

151 P
FURTHER PROGRAM ENTRY IMPOSSIBLE
PROGRAM NUMBER UNAVAILABLE
PROGRAM NUMBER ALLOCATED
LABEL NUMBER ALLOCATED
TOOL NUMBER ALLOCATED
RELAY EXT. DC VOLTAGE MISSING
POWER INTERRUPTED
PGM XXXXXXXX UNAVAILABLE
TWO TOOL DEF XXX WITH PGM CALL
CIRCLE CENTRE UNDEFINED
XXXX
ADDRESS LETTER ALREADY ASSIGNED
BLOCK TOO LONG
G-CODE GROUP ALREADY ALLOCATED
ILLEGAL
G-CODE
BLOCK NUMBER ALREADY ALLOCATED
BLOCK FORMAT INCORRECT
N-CODE MISSING
BLK FORM DEFINITION
INCORRECT
PGM-SECTION
CANNOT BE SHOWN
TOO MANY USER PARAMETERS
PROTECTED PGM
ILLEGAL
NC-BLOCK
CHAMFER NOT ALLOWED

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 8
Section 2.2.2

DR. JOHANNES HEIDENHAN GmbH


D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

Fault

descriptions

WJU Display

THC 151

(flashing)

X-MEASURING
Y-MEASURING
Z-MEASURING
AXIS 4 MEAS.

SYSTEMDEFECTIVE
SYSTEM DEFECTIVE
SYSTEMDEFECTIVE
SYSTEM DEFECTIVE

EMERGENCYSTOP DEFECTIVE

WRONGREFERENCEPOINT

Fault

cause

Possible

fault

location

.Measurinq system not connected


.C&le damaged
.Glass scale dirty or damaged
.Scanninq head damaged
.Measurinq system supervision
damaged

Measuring

.Fault in the emergency stop


circuit
of the machine (for checking
routine
see Mounting Instructions
and
Interface
Circuit
Control-Machine
manual TNC 151 A/TNC 151 P)
.Defect in Control's
internal
Emergency
Stop supervision

Analoque Board
PLC I/O Board
PIG Interface
Board
SE Board
Teminal
Board

.Traversed-over
reference
point lies
outside of the reference
point end
position
(also see Mounting Instructions and Interface
Circuit
Control
Machine
TNC 151 A/TNC 151 P.
.Defect in Control/machine
interface

Machine (cams/switches
"reference
end-position"
pulse inhibit")

Analoque

system

Board

PLC I/O Board


PLnCInterface
Board
SE Board
Terminal Board

151 P)
(TNC 151 P)
(TMC 151 A)
PIN2 151 A)

(TNC

or "reference
(TNC 151
(TNC 151
(TNC 151
VTNC 151

P)
P)
A)
A)

HEIDENHAIN
DR. JOHANNES

HEIDENHAIN

D-8225 Traunreut'Tel.(08669)

VDU Display

GROSS POSITIONING

31-O

Pault

(flashing)

EMERGENCY-STOP

SERVICE
Page 9
Section

GmbH

cause

With
standard
PLC program,
faulty
reply
from output
A6 ("Lock
for
spindle
on")
to
input
E20 ("reply:
Lock
for
spindle
on")
Fault
message
EMERGENCY-STOP
PLC
appears
only
when no additional
PLC marker
is set for
the fault
message

PC

ERROR A

.Trailing
error
greater
than value
entered
in MP 174.
(see Mounting
Instructions
and Interface
Circuit
Control-Machine
manual
TNC 151 A/
TNC 151 P)
.Deviation
from the intended
position
at
standstill
greater
than the value
entered
in MP 169
(see Mounting
Instructions
and Interface
Circuit
Control-Machine
manual
TNC 151 A/
TNC 151 P)
-Exceeding
the range
for
the continuous
position
supervision
determined
by MP 57.
(see Mounting
Instructions
and Interface
Circuit
Control-Machine
manual
TNC 151 A/
TNC 151 P)
.Relationship
between
output
voltage
and
traversed
distance
outside
of the defined
tolerance.
.Defect
in the pulse
counting
section
(Control
circuitry)
after
the transducer
signal
supervision

MANUAL TNC 151


2.2.2

Possible

fault

Terminal

board

location
(TNC

151 A)

In the Case of Gross


Positioning
Errors
A/B/C/D
the fault
could
lie
with
any
element
in the closed
loop
servo
system.
ie Control
hardware
(CLP Processor
Bra.),
n
11
(Analogue
Brd.),
servo
II

amplifier
"

(offset
(gain

motor,
tacho,
measuring
system,
external
forces
acting
inappropriate
MP values

voltages),
too low),

on drives,
programned.

Aid:
1. Program
MP 54 (acceleration)
small
as possible.
2. Adjust
rapid
traverse
(as
trailing
error
as possible).
3. Gradually
increase
MP 54.
If this
does not help:
fault
in the Control
hardware
loop)
or in the machine

as
small

(closed

HEIDENHAIN
DR. JOHANNES
D-8225Traunreut

SERVICE MANUAL TNC 151


Page 10
Section
2.2.2

HEIDENHAIN GmbH
.Tel. (08669) 31-O

Kundendienst

VDU Display

Fault

(flashing)

GROSS POSITIONING

ERROR B

Possible

cause

.The Control-calculated
tage
(implied
by
than
10 V

trailing

analogue
error)

output
volis greater

see

above

GROSS POSITIONING

ERROR C

.The analogue
output
voltage
actually
necessary
to obtain
a desired
speed deviates
from
the expected,
calculated
voltage,
by more
than the voltage
programmed
in MP 234

see

above

GROSS POSITIONING

ERROR D

.The actual
position
at standstill
deviates
from the intended
position
by more than the
distance
programmed
in MP 169

see

above

.Ambient
temperature
inside
the TNC has exceeded
+65Y
.Fault
in the temperature
supervision

Ambient

TX-OPERATING

TEMP.

ExCEeDED

Analogue

fault

location

temperature
Board

of

Control

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 11
Section
2.2.2

DR JOHANNES HElDENHAlN GmbH


D-8225 Traunreut .Tel. (08669) 31-O
Kundendienst

CRT display

Fault

(flashing)

ERROR IN PLC PROGRAM

....

Possible

origin

Fault
with
Description
36 . ...40)

safety-related
marker
manual
TNC 155 A/TNC

fault

(see PLC155 P pages


PLC Program,

Start
Error

Key
with

Rapid

traverse

Direction

Feed

Start

PLC positioning

X-axis

Start

PLC positioning

Y-axis

Start

PLC positioning

Z-axis

Start

PIG

Direction

key

x+

Direction

key

X-

Direction

key

Yi

Direction

key

Y-

Direction

key

z+

Direction

key

Z-

Direction

key

IV+

Direction

key

IV-

Undefined

macro

safety-related

marker

key

latch

key

release

positioning

called-up

IV-axis

via

location

PLC marker

Main

Processor

Board

HEIDENHAIN

SERVICE MANUAL
Page 12
Section
2.2.2

DR JOWNES
HEIDENHAJN GmbH
D-8225 Traunreut .Tel. (08669) 31-O

151

TNC

Kundendienst

VDU Display
TNC-ELECTRONICS

* CRC = Cyclic
** MID = Macro

Fault

(flashing)
DEFECTIVE

Redundancy
Instruction

cause

False
CRC CHECK-SUM*
of machine-related
data excluding machine
parameters.
(Baud rate,
limitation,
preset
etc)
False
CRC CHECK-SUM*
(machine
parameters)
False
CRC CHECK-SUM*
(user
memory)
Integrated
Test Program
execution
incomplete
Software
error
Main Processor
Software
error
CLP Processor
MID interrupt**
CLP Processor
CLP Processor
instruction
stack
overflow
False
instruction:
Main
Processor
-CLP
PrOCessOr
False
instruction
(display
mode):
Main
Processor
--cCLP
Processor
CLP Processor
RAN
Overflow
interrupt
MID interrupt
Main
Processor
Equipped
with
incorrect
language
version
FFFF Main Processor
RAM E&$8...

Check
Detection

Possible
Main

fault

location

Processor/Memory

Memory/Main

Processor

Memory/Main
Processor
Main
Processor/Memory

Main
CLP
CLP
CLP
CLP

Board

Board
Board
Board

Processor
Board
Processor
Board
Processor/Main
Processor
Processor
Board
Processor/Main
Processor

CLP-Processor/Main
CLP Processor
Main Processor
Main Processor
Main Processor
Main
Processor

Processor
Board
Board
Board
Board
Board

Board
Board
Board

HEIDENHAIN
DR JOHANNES

D-8225Traunreut

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 13
Section
2.2.2

GmbH

.Tel.(O8669)31-0

Kundendienst

VDU Display
CHECK-SUM

Fault

(flashing)
ERROR

Possible

cause

fault

location

xx00

CRC CHECK-SUM error


with
EPROM 4
XX = correct
CHECK-SUM value
00 = code for
faulty
EPROMs

Main

Processor

Board

xx02

CRC CHECK-SUN

with

EPROM 5

Main

Processor

Board

xx04

with

EPROM 6,7,8

Main

Processor

Board

XXOA

with

EPROM 9

Main

Processor

Board

(PLC program)

XXOB

with

EPROM 9

Main

Processor

Board

(PLC

xxoc

with

EPROM A

Main

Processor

Board

xx10

with

EPROM B,C,D

Memory

Board

xx17

with

EPROM E

Memory

Board

XX18

with

EPROM F

Memory

Board

XXlA

with

EPROM

Memory

Board

XXlC

with

EPROM H,K

Memory

Board

XXlF

with

EPROM K

Memory

Board

xx20

with

EPROM 2

CIZ

error

Processor

Board

dialogue)

xx21

CRC CHECK-SUM
CLP Processor
the operating

error
in RAN area on the
Board
in which
a part
of
program
is stored

CLP Processor

Board

xx22

CRC CHECK-SUM

error

CLP Processor

Board

(export

version)

XX23

CRC CHECK-SUM
CLP Processor
ating
program

error
in the RAM area on the
Board where
part
of the operis stored

CLP Processor

Board

(export

version)

XXFF

CRC CHECK-SUM error


PLC Marker
2815 is

with

with
set

EPROM 3

PLC-RAM

Main

Processor

Board

nelueluniillu

DR. JOHANNES
D-8225Traunreut

HEIDENHNN GmbH
.Tel.(O8669)
31-O

Se&ion

Kundendienst

2.2.3

Testing

SERVICE MANUAL TNC 151


Paae 14

of the VDU and associated

2.2.3

circuitry

The first
objective
is to determine whether the fault is
actually
with the Display Unit, in which case it must be
returned to DR JOHANNES HEIDENHAIN for repair,
or whether
it lies elsewhere,
with the asscociated
circuitry,
in
which case repairs may be possible without returning
the
unit.
The Display Units BE 111 and BE 211 are powered by an 11V
dc supply from the Power Supply Board. This is a possible
source of the fault,
in which case the test and repair procedure continues according to section 2.2.4, Testing of the
mains supply end the Power Supply Unit.
If the fault is not due to a detective
power supply, it is
likely
to be due to the CLP Processor Board, which contains
the control
circuitry
for the Display Unit. This can be
verified
by exchanging the board for one when is known to
function
correctly.
If the fault still
persists
then must be due either to bad
connections
within the TNC (eg on the Connector Board), or
to faults on both the VDU end the CLP Processor Board.
See the diagram opposite for a logical
locating
the fault in the system.

procedure

for

Testing

of the VDU and associated

circuitry.

7 HEIDENHAIN

Blllh

SERVICE MANUAL
Page 15
Section
2.2.4

DR. JOHANNES HEIDENHAJN GmbH


D-8225 Traunreut .Tel. (08669) 31-O

TNC 151

Kundendienst

2.2.4

Testing

of

the

mains

supply

and

the

Power

Supply

Unit

The procedure
for testing
the Power
Supply
Unit
is shown in
the flow
diagram
on page 16. As part
of that
procedure,
it
may be necessary
to test
the voltages
at various
points
on
the Power
Supply
Board.
The diagram
below
and the table
opposite
show the locations
of the test
points
(solder
terminals)
on the Power Supply
Board,
and the respective
"nominal"
and "actual"
test
voltages
under
load.
.

6
7
9,10,1

* not
Signal

used

with

designations

.l,lZ

TNC 151
for

the

plug

and test

points.

Fuses

Fl

Test

points

and F2 not
on the

used
Power

on TNC 151
Supply

Board

JOHANNES HEIDENHAIN
for return.
Where
appropriate,
order
exchange
unit.

Defectiw

scannino

head

~~lUENllAlN
DR. JOHANNES
D-8225Traunreut

HEIDENHAIN GmbH
.Tel.(O8669)31-0

SERVICE MANUAL TNC 151


Page 18
Section 2.2.6

Kundendienst

2.2.6

Burn-111 Test

of there being definite


fault condiIn some casee, inspite
tions on the control,
error messages may not be displayed
on
the VDU. However, the Control's
electronics
can be tested
with the help of the Burn-In test program.
This test program is a means of dynamically
testing
the
Control's
hardware and can be used not only for duration
testing but also for fault diagnosis.
The test program is stored on a digital
cassette and can be
loaded into the Control via magnetic tape units ME 101 B/
102 B or ME 101 C/102 C (Program versions
212 902 05/
212 902 07). The test program cannot be loaded into the
Control
if the flashing
error message: "TNC ELECTRONICS
DEFECTIVE" is present on the VDU. In this case, the faulty
board must be determined by exchanging each board in turn
until
the fault is eliminated.
However, before exchanging
any board, it is advisable
to check the output voltage
from the Power Supply Unit (see section 2.2.4).
TO run the Burn-In test program it is neccessary to have a
set of Burn-In Test Adapters.
Figs. 2 to 5 show pictorial
of each individual
adapter.

and schematic

representations

Depending on the type of Control,


(TNC with either
a standard
SE interface
or with an external
PLC I/O Board) the appropriate adapters must be connected as shown in fig. 1.
It is important to have the correct test program for the
type of Control and for the Control's
current NC Software
issue. The test programs are listed on page 20. The type of
Control can be determined from the identification
number of
the unit; the issue of the NC Software can be determined from
the NC Software issue number. Both these numbers are found on
the type-plate
on the rear of the Control.

~~IU~NI-IAIN
DR. JOHANNES
D-8225Traunreut

HEIDENHAIN GmbH
.Tel.(O8669)31-0

Kundendienst

Application

of

the

Bum-In

Test

SERVICE MANUAL
Page 19
Section
2.2.6

TNC 151

HEIDENHAIN

SERVICE MANUAL
Page 20
Section
2.2.6

DR. JOHANNES HEIDENHAIN GmbH


D-8225Traunreut~Tel.
(08669) 31-O

TNC 151

Kundandienst

Burn-In

Test

on the

Philips

Control
TYP=

151

for

miniature

FrOUl
NC Software
issue

229

134 99

229

134

95

229

134
134

99
95

229

TNC 151
cassette

Control
Id. No.

TNC 151 A

TNC

Programs

. . .

. . .

. . . 06

. . . 06

Test
dialogue
D

GB

Test Prog.
Id. NO.
230

230

600

601

01

01

Burn-In

Test

on the

Philips

Programs

for

miniature

cassette
From
NC Software
issue

Control
Type

Control
Id. No.

TNC 151 P

229 136

99

229

136

95

229

136

99

229

136

95

TNC 151 P

TNC 151 P

Test
dialogue

Test Prog.
Id. No.

. . .

. . . 06

230

602

01

. . .

. . . 06

GB

230

603

01

r-7 HEIDENHAIN
w

DR.JOHANNES

HElDENHAlN

SERVICE MANUAL TNC 151


Page 21
Section
2.2.6

GmbH

D 8225Traunreut~Tel.(08669)

31-O

Kundendienst

Fig.

1 Interconnections

of

Burn-In

Adapters

and

TNC 151

150A
,-in

nooprer
I II

L'TNCK5
TNC155 Zusiitzl. Burn-in Ad ter
Additional Burn-in AT apter

a)

TNC 151 A/E

b)

TNC 151 P/V

HEIDENHAIN
DR. JOHANNES
D-8225Traunreut

SERVICE MANUAL TNC 151


Page 22
Section
2.2.6

HEIDENHAN GmbH
'Tel. (08669) 31-O

Kundendienst

Fig.

2 TNC 150 A Burn-In

Adapter

(Id.

No.

224

874

ZY)

Xl>
Ail
i,
Jil
,116

Schematic
of interconnections
Burn-In
Adapter
to the Control.

created

by

connecting

the

TNC 150 A

HEIDENHAIN

SERVICE
MANUAL
Page 23
Section
2.2.6

DR. JOHANNES HElDENHAlN GmbH


D-8225 Traunreut .Tel. (08669) 31-O

TNC 151

Kundendienst

Fig.

..r

3 TNC 150 P Burn-In

Adapter

(Id.

No.

224 875

ZY)

.*.

Schematic
Burn-In

of interconnections
Adapter
to the Control.

created

by

connecting

the

TNC 150 E

r
m

1 HEIIJENHAIN
DR. JOHANNES
D 8225Traunreut

HEIDENHAIN GmbH
'Tel.(O8669)
31-O

SERVICE
Page 24
Section

Kundendienst

Fig.

4 PLC Adapter

(Id.

No.

224 873

MANUAL TNC 151


2.2.6

ZY)

Internal
Additional
facility

circuitry
circuitry

schematic:
for overload

Internal
Standard
bipolar

circuitry
circuitry,
switch-over.

schematic:
with
unipolar/

HEIDENHAIN
DR JOHMINES
D 8225Traunreut

SERVICE MANUAL
Page 25
Section
2.2.6

HEIDENHAJN GmbH
Tel. (08669) 31-O

Kundendienst

Fig.

5 TNC 155 Additional

Burn-In

Adapter

(Id.

No.

228

881

ZY)

r----

s&pin

14-pin

_---

7-pin

Internal

connections.

--

TNC 151

SERVICE MANUAL TNC


Page
26
section

Kundendienst

Loading
(Burn-In

the Burn-In
test

test

loaded)

1. Connect the Magnetic Tape Cassette Unit


V-24 socket on the sear of the Control.

(ME 101/102)

to the

2. Prepare the ME unit to down-load the test program to the


Control by inserting
the appropriate
program cassette (see
list,
page 20) and pressing the following
buttons:

I-

2.2.6

The necessary code number for reading in the Burn-In


program is entered by pressing the following
keys:

program

program not already

151

El-

as often

as necessary

to obtain

test

the display:

"CODE NUMBER=", and then:

(Errors in entering
these numbers can be corrected
sing clCE )4. The data transfer
is then initiated
by pressing:

by pres-

E3l
During the loading
unit, the following

of the Burn-In
dialogue will

test
program
be displayed:

from the NE

"POWERINTERRUPTED
EXTERNAL DATA INPUT"

Fig.

6 Initialization

of ME unit

3. Control must now be prepared:


After applying power to the Control,
ries out a memory test. During this
MEMORY

If necessary, the MB unit will first


rewind the cassette
before transmitting
the data, blockwise,
to the Control.
user-programs
already loaded/programmed
into the Control
will be unaffected
by loading the Burn-In test program.

it automatically
time the dialogue

Car-

TEST"

will be displayed
on the MU.
Upon completion of this test,
by
"POWER INTERRUPTED".

the dialogue

will

be replaced

tape
Any

5. The Burn-In test program occupies both tracks of the cassette tape. Consequently,
when all the data from the first
track has been transferred,
the following
dialogue will be
displayed:
"EXCHANGE CASSETTE - ME START
EXTERNAL DATA INPUT"
To complete the data transfer,
turn over the cassette and
press the START button on the ME unit. The VDU will again
display the dialogue.

HEIDENHAIN
DR. JOHANNES HEIDENHAIN
D-6225Traunreut~Tel.(08669)

SERVICE MANUAL TNC 151


Page 27
Section
2.2.6

GmbH
31-O

Kundendienst

"POWER INTERRUPTED
EXTERNAL DATA INPUT"
6.

After
completion
will
rewind
the
question
"EXTERNAL

UNIT

Any other
display
an incorrect/faulty

of a sucessful
data transfer,
the ME unit
cassette
and the VDU will
display
the

CONNECTED
implies
test

?"
either
program

a transmission
cassette.

error

or

Fig.

7 Loading

and

Initialization

of

Burn-In

Test

Program

HEIDENHAIN

SERVICE MANUAL
Page 28
Section
2.2.6

DR. JOHANNES HElDENHAlN GmbH


D-8225 Traunreut Tel. (08669) 31-O

TNC 151

Kundendienst

Re-initialization

of

a previously

loaded

Burn-In

test

program

The possibility
exists
that
the Burn-In
test
program
has been
loaded
and then the power
removed.
In this
situation
the buffer
batteries
will
maintain
the program
in memory until
the mains
is restored.
It is also
possible
that
the system
has been warm-booted,
during
the execution
of the Bum-In
test,
by pressing

Under
both
of
to be followed
The
test

Control
takes
MEMORY

will
Upon
by

will
automatically
approx.
17 sec.

IMPORTAIJT
Only press

the following
the Burn-In
carry

during

procedure
is
test
program:

out a memory check.


which
time the dialogue

This

TEST"

be displayed
completion

"PRESS

these
circumstances
in order
to restart

of

on the VDU.
this
test,

the

dialogue

will

be replaced

NOENT KEY"

the

key

if you wish
to cram
the normal
operating
To restart
the Bum-In

the Burn-In
test
system.
t&t
priqramm

program
press

and return

to \

The

Any
and

following

dialogue

"EXTERNAL

UNIT

other
display
the program

will

CONNECTED

then

be displayed:

?"

implies
an error
in
must be reloaded
from

the
the

stored
cassette.

test

program

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 29
Section
2.2.6

DR. JOHANNES HEIDENHAlN GmbH


D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

Continuation

of

The remainder
in conjunction
1. Beginning

of the initialization
with
the flow
diagram
with
the display

"EXTERNAL

the

UNIT

Bum-In

test

CONNECTD

procedure
of figure

2.

must be described
9, page 31

?"

which
refers
to the use of an externai
operator
must respond
by pressing

The lines
of dots
represent
the individual
keys
in each of
the four
keying
fields.
The keys must now be pressed
once
in a defined
sequence,
each,
in order
that
the Control
can
check
that
each key is making
contact
and delivering
the
correct
code to the keyboard
interface.
The keying
sequence
is as follows:
top right
set of 20 keys
=I
b)
top left
set of 10 keys
middle
left
set of 20 keys
Cl
d)
bottom
right
set of 10 keys
In each case,
the sequence
is from
left
to right,
beginning
with
the top row.
For each correct
key-push,
the respective
dot on the VUU
will
be replaced
with
a. "*".
If an incorrect
code is received,
the keyboard
test
will
start
again
from the beginning.

initialization

test

computer,

the

A check
is now automticall$
carried
out,
test
program
data has nbt been corrupted
error
is detected,
the display

tb ensure
that
in any way.
If

the
an

If the keyboard
before
a power
is not displayed.
has been stored
the sequential

"REREAD-IN
PROGRAM XXXX
CHECK SUM ERROR"
will
from
3.

appear
on the
the ME unit.

VDU,

and

the

test

If the keyboard
test
has not already
prior
to a mains
interruption)
the
this
test
will
now be displayed:
"JUMP
The

OVER KEYBOARD

keyboard

test

can

TEST

program

been
option

must

be reloaded

carried
out
of carrying

be skipped

by pressing

the

key

q
Any other
case the
.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

key will
following
.
.
.
.

.
.
.
.

.
.
.
.

.
.
.
.

cause
display

4.

If the keyboard
test
an error
message
has
error
message
will
be
for
an interrupt
(see

5.

In the case of a Control


designed
for
PLC I/O Board,
the following
text
will
following
a successful
keyboard
test:

(eq.
out

?"

"0,
the test
to be carried
will
appear
on the

. . . . . . . . . . ..E
..E
. . . . . . . . . - . . E
..E

out,
VDU:

in

which

test
has previously
been carried
out (eq
failure),
the option
of carrying
out the test
In this
case,
assuming
no errrx
message
from a previous
run,
the program
jumps into
tests
(see page 32).

1,

OR 2 PC-BOARD

has previously
been carried
been stored
from an earlier
displayed
and the program
point
7).
use with
appear

out,
and
run,
this
will
wait

an external
on the VDU,

?"

This
refers
to the number of
nected
to the Control
during
with
the appropriate
numeric

external
the test,
key.

PLC I/O Boards


conand must be answered

7 HEIDENHAIN

mlh

SERVICE MANUAL TNC 151


Page 30
Section
2.2.6

DR. JOHANNES HEIDENHAJN GmbH


D-8225 Traunreut Tel. (08669) 31-O

Kundendienst

6.

The final
step
of the full
initialization
calibration
of the two potentiometers
the Control.
These must be adjusted

procedure
is the
on the front
panel
of
to give
the display:

"TEST INT.PCT,
BATTERY TRIGGER
OVERRIDE POT ADJUST:
100
SP. ROT. SPEED ADJUST:
100"
If necessary,
the caps of the knobs
securing
screws
slackened,
and the
tightened
in the 100% position.
7.

must
knobs

be removed,
the
realigned
and

At the beginning
of the initialization
procedure,
interruptions
of the program
are inhibited.
After
completion
of
the initialization,
interrupts
are enabled
to permit
jumps,
at any time,
to various
points
in the test
procedure.
Once the interrupts
have been enabled,
the test
program
can
be interrupted
by pressing
one of a number
of keys.
The keys:

fbr example,
initialization

cause restarts
routine,
as
System

isl
q

re-boot

EXTERNAL

"JUMP

"0,

1,

at various
points
during
shown in figs.
8 and 9.

UNIT

CONNECTD

OVBRKBYBOARD

OR 2 PC-BOARD

?"

TEST ?"

?"

"TEST INT.POT,,BATTERY
TRIGGER
OVERRIDE POT ADJUST:
100
SP. ROT. SPEED ADJUST:
100"

the

Other
interrupts
the following

are
section.

also

possible;

these

are

described

in

1 HEIDENHAIN

llllllh

SERVICE MANUAL
Page 31
Section
2.2.6

DR. JOHANNES HEIDENHAJN GmbH


D-8225 Traunreut .Tel. (08669) 31-O

Kundendienst

Fig.

9 Complete

initialization

of

the

Burn-In

test

program

TNC 151

7 HEIDENHAIN

Ih

SERVICE MANUAL TNC 151


Page 32
Section 2.2.6

DR. JOHANNES HElDENHAlN GmbH


D-8225 Traunreut Tel. (08669) 31-O

Kundendienst

sequential
(duration)
tests
Before starting
these tests, check that all test adapters are
including
the connection to the V-24 intercorrectly
connected,
face socket.
The following

tests

are included:

a) Key El
"TEST INT.POT, BATTERY TRIGGER"
- Front panel potentiometers
must be set to 100 2 2%
b) Key cl0
"EPROM TEST CPU"
- The check-sums of all EPROMs accessible
Processor Board CPU are checked.
cl Key El
"RAMTEST CPU BOARD
- Checks the RAM on the Main Processor

to the Main

h) Key

El

"INPUT/OUTPUT TEST 1. PC BOARD" (only TNC 151 P)


The PLC I/O Board outputs are resistively
loaded and connected to the inputs by means of the PC Burn-In Adapter. Each
output is connected to 2 inputs. By writing
"1"s to the outinputs, the Control is
puts, and checking the corresponding
able to deduce whether a fault is on an input or an output.
If a fault is detected
(a "0" on an input) the input conditions are displayed
on the VDU:
eg. :
"INPUT/OUTPUT TEST 1. PI& BOARD
OUTPUT (or input) FAILURE ,~
INPUT
0
20
40
60

01234567890123456789
01111111111111111111
11111111111
111111111111
1111

01111111
1111111

Board
BURN IN TIME: x,x HRS"

d) Key El
"RAMTEST MEMORYBOARD"
- checks the RAM on the Memory Board.
This test must not be interrupted
by a mains failure

e) Key
"TEST PC PAM"
- Checks the RAM where the PLC data is held
inputs, outputs,
timers, counters etc).

always a zero

Input 31 is used to monitor a 20 ms monostable pulse generated on the Emergency Off output.
If the duration
of this
pulses falls outside its tolerance
limits,
a fault condition will be displayed:
eg. : "MONOFLOPTIME TOO SHORT 2OMS"

(markers,
This pulse can be generated manually by individual
PrOoEing
of the key cl+ or, repetitively,
by pressing the key site
in
quick succession.
This repetitive
mode will be indicated
by
a "1" at input position
31 on the VDU.

f) Key El
"TEST STATIC RAM
CLP PROCESSORBOARD"
g) Key El
"PC INSTRUCT DECODER, ACCU-FF TEST"
The circuitry
used for decoding and carrying
instructions
is tested.

'i

To aid in locating
an I/O fault,
each output
individually.
By pressing the key
out the PLC

can be driven

El
(after
a short delay) the VDU will display the input
tions when only output 0 is being driven high.

condi-

I
I

HEIDENHAIN
DR. JOHBNNES

SERVICE MANUAL TNC 151


Page 33
Section
2.2.6

HEIDENHAIN

D-8225Traunreut

GmbH
.Tel. (08669) 31-O

Kundendienst

eg. : 'INPUT01234567890123456789
0

10000000000000000000
00000000000010000000

20
40
60

0001

All

i)

(always
a "1")
EO, E32
the key

n)

El
successive
outputs
(in ascending
or in descending
order
with
the

outputs

can

El
be cleared

with

the

order)

to

2OhV,

w,

j)

Key El
"TEST V24-INTERFACE"

k)

Key El
"TEST 3D-SCANNER
INTERFACE"
- Checks
the interface
to the

f) Key
q
"TEST SERIAL
the

HANDWHEEL
interface

INPUT"
to the

9,5v

Touch

o)

TEST"
values
of the
system
inputs.

Key El
"TEST REFERENCE IMPULSE INPUT"
- Checks
the effect
of a signal
pulse
inputs.

circuitry

applied

to

which

the

moni-

reference-

Key
"TEST TRANSDUCER INPUTS,
EXE"
- Checks
the effect
of signals
system
inputs.

applied

to

the

measuring

key

Key
"EXT. PDT, ANALCG OUTPUT TEST"
Five
external
relays
within
the TNC 150 A/P Burn-In
driven
from outputs
Al6 - A20, are used to connect
logue
outputs
X, Y, Z, IV, S, in turn,
to the ext.
pu%(see
figs.
2/3 pages
22/23).
The test
is made
different
voltages:

- Checks

be driven

key

tc

"SUPERVISION
CIRCUIT
- checks
the threshold
tors
the measuring

00000000000000000000

OUTPUT AO, INPUTS


Subsequent
pressing
of

allows
high,

ml Key

Fault
recognition
The detection
of a fault
will
be displayed
on the VDU.
The test
cycle
will
be halted
and the Burn-In
Time stops.
If
one or more faults
arise
during
the execution
of the Burn-In
test
program,
the fault
message
associated
with
the first
fault
will
be stored.
The stored
message
can be retrieved
at any time
by pressing
the key

This
causes
a system
re-boot,
as explained
All
fault
messages
can be cleared
with
the

Probe.

HE 310 Handwheel

Adapter,
the anapot.
inat three

Starting
the sequential
tests
The test
sequence
can be started,
or restarted
at any point
by
pressing
the appropriate
key.(eg
key
8 to begin
with
the V.24
interface
test.)
All
15 keys associate $
with
the sequential
tests
act as interrupts
to the Burn-In
test
program.

Unit

This
ning

key
with

also
the

El
causes
a restart
of
test
"TEST INT.POT,

on page
key

30.

the sequential
tests
BATTERY TRIGGER".

begin-

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 34
Section 2.2.6

DR. JOHANNES HEIOENHAlN GmbH


D-8225 Traunreut .Tel. (08669) 31-O
Kundendienst

Individual
test runs
Each of the individual,
seouential tests can also be made to
run cyclically.
To do this; the test program must be interrnpted with the key

Calibration
Interrupting

check of the Anelogue Board ("TRIMMING ROUTINES")


the Burn-In test program with the key

El
The VDU will

then display:

"1 = CYCLIC
2 = STOPAT FAULT"

Within
ted:

Option 1 means that the test (still


to be selected) will be
run cyclically,
regardless of whether a fault is detected.
Option 2 means that the test will be run cyclically
until
such time as a fault is detected.
When one mode OT the other has been selected, the VDU will
display:
"SELECT TEST"
The desired test must then be selected with the appropriate
key.
Another possible interrupt
to the Burn-In test program is by
means of the key
El
With this key the entire
played on the VDU.

set of ASCII characters

the calibration

mode the following

tests

performance *
- Key cl1 : Reference amplifier
("TRANSMISSION BEHAVIOUR REF. AMP.")
- Key

- Key

- Key

- Key

can be dis-

: Analogue output voltage **


("ANALOGVOLTAGEOUTPUT")
: 32-step monotonic DAC *
("MONOTONIYDAC; 32 STEPS")
: DAC performance *
("TRANSMISSION BEHAVIOUR DAC")
: +/- 1ov analogne output **
("DAC + ANALOGOUTPUT+/- 1OV")

- Key 0.6 : Lrnearity


("DAC +
- Key

0
*
l

text
these

of analogne output *
ANALDG OUTPUTLINEARITY")

: Battery voltage check **


("TEST BATTERYVOLTAGE")
in brackets
tests
are

* Bee follaing

appears
on
not
suitable

l xp1nNtions:

VDU

for

custmr

ye,

can be selec-

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 35
Section
2.2.6

DR. JOHANNES HEIDENHAIN GmbH


D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

Key
: Analoque
output
voltaqe
The performance
of the analoque
output
circuitry
can be checked
by connecting
a DVM to each of the analoque
outputs
(eq X-axis:
pin 2) and selecting
this
test.
Using
the keys
Jl,
pinl,
w.s.t.

24,4mV,
244mV and 2.44V respecincrements
of 2,44mV,
can be sunned
at at each of the analoque
outputs
(X, Y,
S).
the X key is pushed
5 times,
the Y key 3 times,
and the
key once,
the output
voltage
should
read:
(5 x 2,44
mV) + (3,x,24.4
mV) + ( 1 x 2.44
V) = 2,5254
V

voltage
tively
z, IV,
if
eq.:
IV

The polarity

The

output

of

the

can be

Keyq : +/- 1ov

output.,can

cleared

using

analogue

output

be reversed

the

The analogue
outputs
should
generate
+lOV.
The polarity
can be reversed

using

the

key

key

their
maximum
as in test
2.

Key a:
Battery
voltage
check
A "1" will
be displayed
on the VDU if
adequate,
otherwise
a "0" is displayed.

the

battery

output

of

voltage

is

HEIDENHAIN

D? JOHANNES HEIDENHAIN GmbH


D 8225 Traunreut Tel. (08669) 31-O

SERVICE
MANUAL TNC 151
Page 36
Section 3

3. Exchange Information
U&e: All inputs/outputs
from the TNC 151 Control can only be
connected to circuits
which have voltages
conforming
to
VDE 5.73 S8.
Do not disconnect

or connect

plugs

under power!

NC machines also need protection


and installation
safety as
required
for manually operated machines (e.g. EMERGENCYSTOP).
Their function
should be checked during commissioning
of the
machine and of a new Control.
Before exchanging a Control
noted or stored on magnetic

the machine parameters


tape!

should be

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 37
Section
3.1/3.1.1

DR. JOHANNES HEIDENHAN GmbH


D-6225 Traunreut Tel. (08669) 31-O
Kundendienst

3.1 Exchanging
Control
Units
3.1.1
Procedure
for exchanging
the TNC 151 A/E Control.
1. Gain access to the rear of the Control.
2. Remove the mains
supply.
3. Remove the connector
box cover-plate
from the rear of the
Control.
4. Mark the measuring
system plugs
(X,Y,Z,IV,
Electronic
Han&heel)
and remove them.
5. Disconnect
the VDU from the Control.
6. Disconnect
the Handwheel
Unit
from the Control
(if present).
7. Disconnect
any external
data devices.
8. Disconnect
connector
strips
Jl-J6,
using
a screwdriver
to
prise
the connectors
apart
(Do not unscrew
individual
wires).

prise
art
screwdriver

with

a
cable

removing
the fixing
screws if
9. Remove the faulty
Control,
not already
removed
in 1.
10. Install
the new Control
- check the voltage
selector
position.
11. Check the fuse-rating
(see type-plate).
12. Reconnect
all cables
previously
removed.
13. Obtain
from the type-plate
the Control's
Id. No.,
NC and
PLC Software
Nos.,
and write
them in the machine
handbook.
14. Refit
the connector
box cover-plate.
15. Turn on the mains voltage.
16. Reprogram
the machine
parameters.
17. TNC is now ready to use.

HEIDENHAIN

SERVICE UANUAL
Pago 38
Section
3.1.2

DR. JOHANNES HEIDENHAIN GmbH


D-8225 Traunreut .Tel. (08669) 31-O

TNC 151

Kundendienst
3.1.2

1.
2.
3.
4.
5.
6.
7.
8.
9.

Procedure
for
exchanging
the TNC 151 P/V Control
Gain access
to the rear
of the Control.
Remove the mains
supply.
Remove the connector
box cover-plate
from the rear
of the
Control.
Mark the measuring
system
plugs
(X,Y,Z,IV,
Electronic
Handwheel)
and remove
them.
Disconnect
the VDU from the Control.
Disconnect
the Handwheel
Unit
from the Control
(if
present).
Disconnect
any external
data devices.
Disconnect
connector
strips
Jl-J3,
using
a screwdriver
to
prise
the connectors
apart
(Do not unscrew
individual
wires).
Remove the connecting
cable
P2 to the PL 100 B/110
B from the
Controls.
I

10.
11.
12.
13.
14.
15.
16.
17.
18.

removing
the fixing
screws
if
Remove the faulty
Control,
not already
removed
in 1.
Install
the new Control
- check
the voltage-selector
position.
Check
the fuse-rating
(see type-plate).
Reconnect
all
cables
previously
removed.
Obtain
from the type-plate
the Control's
Id. No.,
NC and
PLC Software
Nos.,
and write
them in the machine
handbook.
Refit
the connector
box cover-plate.
Turn on the mains
voltage.
Reprogram
the machine
parameters.
TNC is now ready
to use.

II

-.?

6113

8113

10
r.

'.

lleIuel\nAllu
DR. JOHANNES

D-8225 Traunreut

HElDENHAlN

Tel. (08669)

GmbH

31-O

Kundendienst

3.1.3
1.
2.
3.
4.

5.
6.
7.

Procedure
for exchanging
the PLC I/O Board
of the PL 100 B/110 B
Remove the fixing
screws of the heatsink
cover-plate.
Remove the heatsink
cover-plate.
Disconnect
the TNC 151 connecting
cable.
Disconnect
connector
strips
Jl-J9,
using
a screw driver
to prise
the connectors
apart.
(Do not unscrew
individual
wires)
Remove the voltage
supply
(+24V and OV)
Remove the fixing
screws of the PL 100 B/110 B unit.
Install
the new unit
following
the above procedure
in
reverse
order.

SERVICE MANUAL TNC 151


Page 39
Section
3.1.3

HEIDENHAIN
DR. JOHANNES

D-8225

Traunreut

HElDENHAlN

SERVICE
Page 40
Section

GmbH

.Tel.(O8669)31-0

MANUAL TNC 151


3.2

Kundendienst

3.2 Board
Exchange
Board
Arrangement
The TNC 151 consists
of three
main sections:
1) The frontplate/Keypad
Board
assembly;
2) The housing/Connector
Board
assembly,
with
five
plug-in
boards,
namely:
.Memory
Board
.Main
Processor
Board
.CLP Processor
Board
.Analogue
Board
.either
SE Board
TNC 151 A/E
or PLC Interface
Board
TNC 151 P/V
Power Supply
Unit
and Terminal
3) The backplate,
assembly.

Board

arrangement

TNC 151 A/AR/P/PR


TNC 151 E/ER/V/VR

PLC 3L/O Board


TNC- -51
3
P
(224~

389/223

Connector

691)

Board

(227.267)

Board

(22:
Power
(227

=4/228
Supply

(with

Board

601)

PLC Interface
(226

16!)\

Bwrd

761)

TNC 151 P/V)

SE Board
- -,
(with
TNC 151 A/E)
Analog
(222

Board
50~2/223

CLP :Processor
(222

580/229

Main.Processor

Memory
(224

Keypad
(224

550)

Board
133)

Board'

Board
843/230

Board
825)

400)

llEllJENllAlN
DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut Tel. (08669) 31-O

caution:

.Please observe MOS protection


measures when exchanging boards.
.Exchange boards with the same assembly no. only.
The assembly no. is impressed on every board, on the
left of the serial no.

SERVICE MANUAL TNC 151


Page 41
Section 3.2
Work area requirements
The TNC 151 contains sub-assemblies
with MOS elements.
Although MOS ICs are equipped with an input protection
diode
network, to eliminate
the build-up
of static charges care must
be taken when handling these elements.
The following
requirements
in the work area must be met:
Prior to working with MOS components or with assemblies containing
MOS elements, all table coverings,
instruments,
tools,
end work personnel must be properly
grounded.
A portable
"MOS-HANDLING-SET" for field
when exchanging the operating
software
TNC 151:

service
is necessary
and/or servicing
the

a conductive

work surface

a wristband
that provides
en electrical
connection
between person and conductive
work surface

a cable
between

that equalizes potential


differences
conductive
work suface and ground

HEIDENHAIN
DR. JOHANNES HElDENHAlN
D-8225Traunreut.Tel.(08669)31-0

SERVICE
MANUAL TNC 151
Page 42
Section
3.2

GmbH

Kundendienst

Exchanging
the pluggable
boards
Unscrew
the 5 mounting
screws
and remove
the housing
cover.
Removing
the boards:
Press
the board
ejector
keys outwards
and pull
out the individual
board
form the top.

Analogue
Board
Before
removing
the Analogue/Analogue
TTL Board
pull
off
and
mark the connector
plugs
for the measuring
system
inputs/
square
wave signal
inputs
and the electronic
handwheel
input.
The connector
sockets
on the board
are coded with
coding
pins.

I
.3

j
_Insezting
the boards:
The connectors
of the boards
is therefore
avoided.
Press
tor
Board
using
the ejector
Main Processor
When exchanging
IC-P19
on the
Main Processor

are coded:
incorrect
the board
firmly
into
keys
tilted
inwards.

and CLP Processor


Board:
these
boards
insert
program
CLP Processor
Board
and IC-P4
Board.

insertion
the Connec-

EPROM's IC-P3
and
to IC-PlO
on the

Board:
During
the exchange
or removal
of the Memory Board
the buffered
RAM will
no longer
be supplied
with
voltage,
which
means that
the machine
parameters
and any user-programs
will
be lost!
Before
inserting
the new Memory Board
plug
in the relevant
EPROMs (EPROM IC-Pll-to
IC-P18),
paying
particular
attention
to their
correct
location
and orientation.
Memory

HEIDENHAIN
DR. JOHANNES HEIDENHAN
D-8225Traunreut.Tel.(08669)

SERVICE MANUAL TNC 151


Page 43
Section 3.2

GmbH
31-O

Kundendienst

Exchanging the Keypad Board:


.Remove the 6 cross-head
fixing
screws from the frontplate.
.Tilt
the frontplate
outwards.
.Remove connectors J13 (feedrate-override
potentiometer)
and
J14 (spindle-override
potentiometer)
from the Connector
Board.
.Remove the ribbon cable connector PlO from the Keypad Board.
.Remove the 7 cross-head fixing
screws which secure the Keypad Board to the frontplate.
.Pull off the Keypad connectors,
Pl to P8 from the Keypad
Board.
.Remove the Keypad Board.

When rebuilding
tors are firmly
the LEDs project
keypad housing.

the assembly, ensure that the keypad connecengaged in their respective


sockets, and that
through the corresponding
bored holes in the

Ih

7 HEIDENHAIN
DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut .Tel. (08669) 31-O

SERVICE MANUAL
Page 44
Section
3.2

TNC 151

Kundendienst

Exchanging
the Power Supply
Unit:
.Remove
the 4 cross-head
mounting
screws
from the rear
of the
Control
(2 screws
are found
in the connector
box).
.Remove
the back wall
with
the Power
Supply
Unit
and Terminal
Board.
.Disconnect
the ribbon
cable
connector,
PI,
from the Connector
Board
(see diagram).
.Remove
the voltage
supply
plug,
P2, from the Connector
Board
(see diagram).

Exchanging
the Connector
Board:
.Remove
the 2 cross-head
fixing
screws
of the V.24 connector
on the rear
of the Control.
.Push the V.24
socket
through
its
recess
in the Control
housing.
.Unsolder
the connectors
to the MU socket
from
the Connector Board
(solder
terminals
1,4,5,6,7,8,10).
Note the colour
of the wire
connected
to each terminal.
.Pull
the Connector
Board
from the front
of the Control
housing.

Comector Board

HEIDENHAIN
DR. JOHANNES
D-8225Traunreut

SERVICE MANUAL TNC 151


Page 45
Section 3.3

HEIDENHNN GmbH
'Tel. (08669)31-O

Kundendienst
3.3

Software

The dialogue
language of the TNC 151 is determined by
IC-PlO (located on Main Processor Board) and is discernible
from the different
Id. NOS. of the programmed EPROMs.

Exchange

The TNC 151 operating

software

is stored

in 17 EPROMs.

- IC-P3, IC-P19 (CLP Processor Board)


- IC-P4... IC-PlO (Main Processor Board)
- IC-Pll..IC-P18
(Memory Board)
Every operating
Software No.
example:

software

is specified

with

an 8 digit

227 001 06 complete software Id. No.


227 001
primary software Id. No.
06 update software index

Each of the 17 progranuned


specified
with an 8 digit

EPROMs (IC-P3...IC-P19)
Id. No.

is

Following
GWXllan
English
French
Italian
Spanish
Swedish
Finnish
Dutch

227 116 CG complete Id. No. of the Prog. EPROM


227 116
primary Id. No. of the Prog. EPROM
C position
on the board
(C = IC-P12, IiEXadecimal counting
llla**er)
G update index

The operating

software

(IC-P3...IC-P8,
(IC-P9)

IC-PlO...IC-P19)

TNC 151 A: Control

with

o NC software and
o PLC standard software

TNC 151 P: Control

with

o NC software and
o PLC standard software,
PLC custom software

or

at this

time

IC-P9 (PLC software)


The standard PLC program (EPROM position
IC-P9)
can be replaced with a custom PLC program for
the TNC 151 P.
IC-P3
The export NC Software differs
NC Software in EPROMposition

in

o NC software
0 PLC software

are available

CD)
(GB)
(F)
(I)
(E)
(S)
(SF)
(NL)

The dot matrix

includes

languages

The Id. No. of the other programned EPROMs are the


same (for a given IC position)
in all languages.
(prerequisite:
same software issue!)
Exception:

example:

dialogue

IC-P19

for

(character

all

VDU displayed
generator).

from the standard


IC-P3.

characters

is contained

SERVICE MANUAL
Paqe 46
Se&ion
3.3

TNC 151

Kundendiemt

Illustration
Illustration

Memory

Board

224 843
230 400

../
..

Main

Processor

left:
below:

Board

222

Arrangement
Arrangement

509

..

of
of

PCBs in the Control


EPROMs on the various

CLP Processor

Board

boards

222

580

..

HEIDENHAIN

SERVICE MANUAL TNC 151


Page 47
Section
3.3

DR. JOHANNES HElDENHAlN GmbH


D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

Software

Exchanae

Caution:

When exchanging
the
protection
procedures!

o The cover of the


the 5 cross-head

Control
mounting

o To exchange
the program,
- Memory Board
- Main Processor
Board
- CLP Processor
Board
have to be removed~from
Thereto,
outwards,
protection

software

observe

the

can be removed
after
screws (top side)
the following
2
3
4
the assembled

lift
the board ejector
pull
out board from
mat.

- After
the software
exchanqe
has been concluded,
the Id.-Nos.
the NC and PLC software
have to be chansed.
The description
plate
for the software
numbers
is found-on
the rear of-the
Control
under the type-plate.

MOS

unscrewing

boards

Control

keys and press


above and lay onto

Id. NO.
'
NC Software
No.,PLC Software
No.-

MOS

o Push screwdriver
blade
carefully
between EPROM and socket,
remove EPROM with extraction
tool
and place
onto MOS
protection
mat.
o Insert
Important:

EPROM into

appropriate

- When exchanging
number
(second
EPROM Id. No..

socket

insertion

EPROMs, observe
the
to last
digit
of the
hexa-decimal
counting

- The EPROM package


direction
as the
- Visually
respective

using

check if
sockets

index must point


ICs on the board.

tool.

position
programed
manner)
in

the

the EPROMs are contacting


after
an exchange.

same

their

The RAM &mory


of the Memory
Board is unbuffered
diving
the EPROM (software)
exchange.
The machine
parameters
and
any stored
user-program
are therefore
erased!
For continued
operation,
reentered
into
memory.

the

machine

parameters

have

to

be

of

neluelunAllu
DR. JOHANNES
D-8225Traunreut

HEIDENHAIN GmbH
.Tel. (08669) 31-O

SERVICE MANUAL TNC 151


Page 48
Se&ion 3.4

Kundendienst

3.4 Replacement
Units
Replacement

Parts

Parts,

Loan/Exchange/Service

Units

TNC 151

In general,
replacement parts are available
for all sub-assemblies discernible
from the wiring diagrams (see section 4.3).
However, it is strongly
recommended that all repairs
and maintenance work are entrusted
to an official
HEIDENHAIN agency.
No responsibility
can be accepted by DR. JOHANNES HEIDENHAIN
GmbH for repairs undertaken by anyone else.
The list on page 49 shows the Id. Nos. and names of all parts
available
for the TNC 151. These parts can be ordered from the
department Kundendienst
(Customer Service)
at HEIDENHAIN
Traunreut.
It is of utmost importance,
when ordering,
to give
(i) the Id. No., (ii) the name, in German, and (iii)
the
quantity
of each part required.
Telexed order should be sent
to the Kundendienst Telex: 17 866 982 or Teletex 866 982.

Loan, Exchange,

Service

Snits

In order to keeep machine down-time as short


HEIDENHAIN offers
a loan and exchange Senh3?.

as possible,

Loan units
Loan units are available,
free of charge, for the duration
of a repair carried
out at HEIDENHAIN Traunreut
or by an
official
HEIDENHAIN agent. The only charges to the customer
are the shipping charges.
Exchange units
An exchange unit can be requested for a unit that is returned for repair.
This exchange unit is equipped with the
latest hardware and software issue and is externally
in
excellent
condition.
The only charges to the customer in
this case are for the repair of his own unit.
Transaction
Requested loan 01
of request,
or the
is available
from
A customer's
faulty
HEIDENRAIN within

exchange units are shipped on the


following
day, provided
that the
our stock.
unit should be returned
to DR.
14 days of receiving
the exchange

date
unit
JOHANNES
unit.

Service units
Service units are new units which are used for service
purposes and can be obtained from DR. JOHANNES HEIDENHAIN
at non-repeatable
discount prices.

IlElUCNnAlN
DR. JOHANNES
D~8225Traunreut

HElDENHAlN GmbH
.Tel.(O8669)
31-O

SERVICE MANUAL TNC 151


Page 49
Se&ion
3.4

Kundendienst

Id.

No.

229 134
229 134
229 135

95
99
95

229
229
229
229
229

135
136
136
137
137

99
95
99
95
99

TNC
TNC
TNC
TNC
TNC
TNC
TNC
TNC

151
151
151
151
151

A/E mit
1280 SBtzen
(with
A/E mit 3160 Satzen
(with
AR/ER mit
1280 Satzen
AR/ER mit 3160 S?&zen
P/V mit 1280 SBtzen
151 P/V mit
3160 SZtzen
151 PR/VR mit 1280 SAtzen
151 PR/VR mit
3160 Satzen

223
223

836
216

. .
. .

PL 100 B Leistungs-Pl.
PL 110 B Leistungs-Pl.

(PLC
(PLC

212
222

300
674

. .
..

BE 111 Bildschirmeinheit
BE 211 Bildschirmeinheit

(9" VDU)
(12" VDU)

212
216
225
224
230
222
223
222
222
227
212

282
394
037
843
400
502
SSO...
509
580
601
387

.
.
.
.
.
.

.
.
.
.
.
.

.
.
.
.

.
.
.
.

Gehause,
Frontteil
TNC
GehZuse,
kompl.
GehSuse,
Tastatur-Vorsatz
Pl.,
Speicher-3160
SAtze
Pl.,
Speicher-1260
SAtze
Pl.,
Analogteil
- Sinus
Pl.,
Analogteil
- TPL
Platine,
Hauptrechner
Pl.,
Regelkreisrechner
Platine,
Netzteil
Platine,
EntstBr

(Front
panel)
(Housing
assy.)
(IS0 format
keypad)
(Memory
Brd.-3160
Blk.)
(Memory Brd.-1280
Blk.)
(Analogue
Brd.-Sinewave)
(Analogue
Brd.
- TPL)
(Main Processor
Bra.1
(CLP Processor
Bra.)
(PSU Board)
(Mains
Filter
Board)

I/O
I/O

1280
3160

blocks)
blocks)

Board)
Board)

Id.

No.

227
226
228
228
224
227
213
217
217
228
202
213
215

278
761
164
166
825
267
204
737
532
168
370
206

091

NEiIE
.
.
.
.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.
.
.
.
.

Platine,
SE
(SE Board)
Platine,
PC-Interface
(PLC Interface
Brd.)
Platine,
Klemmleiste
(Terminal
Brd.
for A/E units)
Platine,
Klemmleiste
(Terminal
Brd.
for P/V units)
Platine,
Tastatur
(Keypad
Board)
Platine,
Stecker
(Connector
Board)
Tastenfeld
kompl.-20
Tasten
(20-key
keypad
assy.)
Tastenfeld
kompl.-10
Tasten
(lo-key
keypad
assy.)
Halter,
Batterie
kompl.
(Battery
holder
assy.)
Potentiometer
kompl.
(Potentiometer
assy.)
SpannungswZhler
m. Si.-halterWoltage
selector+fuse)
Klemme N&z3 pol.
kompl.
(3-way
mains
corm.)
Trafo
BV 15714
(Transformer)

llellJelullAllu
DR. JOHANNES
W3225Traunreut

HEIDENHAIN GmbH
.Tel. (08669) 31-O

SERVICE MANUAL TNC 151


Page 50
Section
4/4.1

Kundendienst

4.

Additional

4.1

Block

- Input/Output
system
inputs,

Information
Diagram

enclosed
unit.

(e.g.
outputs,

keypad,
LEDs,

screen,
measuring
V.24 interfaces
etc.)

Description

General
The TNC 155 block
diagram
shows, in simplified
form,
the internal functional
units
of the control,
their
relationship
to the
various
boards,
and their
interconnections.
The graphic
layout
of the diagram
and the way it is included
in single
sheets.
- the representation
of any of the TNC 155 models
(A/AR/P/PR),
- simplified
representation
of functional
processes
Numbers
functional

facilities
analog

in

dashes

inform

about

the

board

and its

The functions
microprocessor

of the control
are
systems
as follows:

divided

"Main Processor
System"
- Keyboard,
LBDs
- User Program
Interpreter
- Provision
of programming
"environment"
- Generation
of PLC program
addresses
* - Transfer
of input
and output
states
face Board,
SE Board and PLC RAM
* - Control
of the V.24 interface

between

the

two

between

PLC Inter-

1.

2.

Simplified
-

Description

of

the

TBC 155

(Block

"CLP-Processor
System"
- Ascertainment
of instantaneous
- Interpolation
Calculations
- VDU Control
* - Demand Speed Values
to DAC
* - Interface
with handwheel
unit

Diagram)

Board
(1)
Board
(2)
Main Processor
Board
(3)
CLP Processor/Graphic
Board
(4)
Analogue
Board/Analogue
Board TTL (5)
with SE Board
(6) it corresponds
to a A(E)-Type;
without
SE Board,
with PLC Interface
(61, however
with PIG I/O-Board(s),
it corresponds
to a P(V)-Type
respectively,
PR(VR)-Type
- Power Supply
Board
(7)
- Terminal
Board
(8)

* Serial

Keypad

data

transfer

via

positions

CRU bus.

Memory

The functional
processes
of
two microprocessor
systems,
- Microprocessor
(TMS 9995)
- Program
Memory (EPROMs)
- Write-Read
Memory
(RAMS)

the control
are
each comprising:

divided

Main

Processor

Unit

- Primarily
on the main processor
- The operating
system software

is

board
held

and the memory


in EPROMs:

board.

or,
-30.1-30.3-30.3-2obetween

IC-P4
(not mapped)
IC-P5 . ..IC-P88
IC-PlO
(dialogue
language)
IC-Pll...IC-P18

Main
Memory

Proc.
Board

Board

neIurlunAllu
DR. JOHANNES HElDENHAlN
D-8225Traunreut.Tel.(08669)31-0

GmbH

SERVICE MANUAL TNC 151


Page 51
Se&ion
4.1

Kundsndienst

- The RAMS -30.2on the main processor


board can be accessed
either
by the main processor
-3O- or by the CLP processor
-4o-.
The intended
coordinates,
programmed
feed,
display
texts
etc.
can therefore
be transferred.
These RAMS also serve as register
file
memory for the main
processor
-3o-.
, and (under certain
circmUser programs,
machine
parameters
stances)
the PLC program
are programmed
in RAMS -20.1-.
- The 16-bit
address
mapper -31-.

bus

- The keyboard
controller
LEDs and scanning
the

is

extended

-32- has the


keypads
-32.1-

to

20-bit

by a memory

task of driving
the
on the front
plate.

- The main processor


is connected
with V.24 interface
-34via a (serial)
CRU-bus.
This interface
is used to exchange
data by means of a magnetic
tape unit
(ME) or, respectively,
an external
processor.
- The PLC program
contained
in IC-P9
-33.1is
'1-bit-PLC-processor"
-33- mounted
discretely
processor
board.
The input
and output
states
4k x 1 PLC-RAM -33.2-.

processed
by the
on the main
are stored
in a

- I/O-Functions:
a) TNC 151 A-Versions:
24 galvaf;ically
separated
inputs
(EO to E23) -6O- and 24
floating
relay
contact
outputs
(A0 to A22 + emergency
stop)
-61- on the SE Board.
The inputs
and outputs
are protected
on the terminal
board
(A version)
by special
protective
resistances
5.lk
ohms -8O- and 47 ohms -80.1-.
Protective
resistances
should
never be replaced
with normal
resistances!
The Analogue
outputs
are led via LC-filter
-81- as protection
against
the oscillation
of analogue
outputs.

b) TNC 151 E-Versions:


The inputs
and outputs
are loaded
on external
PLC
I/O-board
(e.g.
PL 1OOB or, respectively,
PL 100B)
which are driven
by the main processor
-3O- via the PIG
interface
board.
The data is serially
transferred
via
the CRU-bus.
All lines
of this
bus as well as the
required
addresses
are galvanically
separated
by the
optocouplers
-6O- and are converted
from the TTL level
(5V) to the MOS level
(12V) by means of a level
converter
-61-.
Thus a higher
noise
immunity
is obtained.
Under the control
of CRU addresses
63 programmable
inputs
(EO to E62) -E2- located
on the PLC I/O board are multiplexed
on CRUIN 1 line.
If 2 PLC I/O boards
are connected
the inputs
from the 2nd board
are multiplexed
on CRUIN 2.
On the PLC interface
board either
CRUIN 1 or CRUIN 2 are
selected
-64- and are led to the main processor
via CRUIN.
The serial
CRU OUT signal
is converted
in 31 outputs
via a
serial-parallel-converter
-El.l-.
The outputs
(each having
its own current
supervision
-El-)
are transferred
via line
drivers
to the machine
interface.
- An overloaded
output
only switches
off during
the period
of the overload.
- If the current
supervision
detects
overcurrent
no
emergency-stop
results
in the standard
PLC program.
The input
E63 is used to indicate
an overloaded
output
to
the main processor
-3O-.
PL 100B: 31 unipolar,
programmable
outputs
+
emergency-stop
protected
against
overload.
PL 1lOB:
26 unipolar,
programmable
outputs
+ 5 bipolar
outputs
and emergency
stop protected
against
overload.
On the PlC I/O board a 12V voltage
is generated
by an
external
24V supply.
On the PLC interface
board
this
12V
voltage
is transformed
in a 5V voltage
for its TTL modules.

ncIlJelunAll\
DR JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut Tel. (08669) 31-O

SERVICE MANUAL TNC 151


Paae 52
section

Kundendienst

CLP Processor/Graphic
- Primarily

Unit:

on the CLP processor/graphic

- Operating system is contained


(32k x 8).

board.

in EPROM IC-P3 -40.1-

- The main task is the calculation


of the instantaneously
intended values of the analog output voltages
dependent on:
.the instantaneous
actual positions
.the programmed intended position
.the distance of the intended position
(influence
on deceleration
ramp)
.the programed
feed rate
.the fast traverse
rate* determined per machine parameter
.the setting*
of the override
end feed potentiometer
The calculating
speed requires
a wait-free
RAM -40.2-- The measuring system signals are processed on the analog
board. These signals are amplified
at first
-50.1- and
then subdivided
-5O- by delaying
(phase shifted)
and
combining them differently.
The subdivided
0 degree,
90 degrees and RI signals are then led to the gate arrays
-42- of the CLP processor board. The gate arrays are
especially
developed LSI circuits
consisting
of different
gates and counters in which the direction
of the movement
and the number of pulses are calculated.
This information
can then be scanned by CLP processor -4O- to ascertain
the actual values of the axes.
- The symmetry, the on-to-off
ratio and the amplitude of the
system signals are constantly
controlled
by a supervision
circuit
-5O-.

4.1

- The signals from the handwheel (if present)


are shaped via
the functional
block -53- and are also processed by the CLP
processor.
- If the distance between the control and measuring system is
more then 2010, an EXE has to be interposed.
The measuring
signals are thus already amplified,
subdivided,
evaluated,
supervised
and converted
in TTL signals.
An "R" version of
the control
is used accordingly
(e.g. TNC 155 AR) equipped
with a combined EXE connection
for X-, Y-, and Z-axis and
an analog board TTL. The input amplifiers
and the wiring
for the signal subdivision
are replaced with line receivers
-5O- on this analog board whose outputs are directly
connected to the gate arrays -42- on the CLP processor board.
The supervision
signal of the EXE is also buffered
-5O- and
transferred
to the CLP processor board. The signals of the
handwheel are likewise
processed -53- as on the "normal'
(sine) analog board.
- If instead of linear position
transducers
incremental
encoders are used to ascertain
actual values a reference
pulse
appears once per revolution.
Since only one reference
pulse
is to be evaluated
all other reference
pulses of the axes
X, Y, Z, IV are inhibited
on the analog board -5O-. The
signal lines are connected with the analog board via the PLC
I/O board and the PLC interface
board. The level conversion
MOS/TTL as well as the galvanic
decoupling
is carried out
on the PLC interface
boards via -61- and -6O-.

ll~lUEN~iilN
DR. JOHANNES

D-8225

Traunreut

HEIDENHAIN

GmbH

SERVICE MANUAL TNC 151


Page 53
Section 4.1

.Tel.(O8669)31&0

Kundendienrt

- The data of the CLP processor is transferred


to the analog
outputs via the serial CRU bus. The digital
output values
calculated
for all axes are multiplexed
on the CRU OUT line
and are converted
in a 12 bit parallel
format on the analog
board. These successive digital
values are then converted
in analog values (voltages)
by means of a DAC -52.1(digital-analog-converter).
These voltages
are compared with the
adjusted values of the override
and feed potentiometers
-52- and the results
are transmitted
to the CLP processor
via CRUIN. The output voltages
can thus be adapted to the
values adjusted by the override
or, respectively,
the feed
potentiometer.
The X-, Y-, Z-, IV- and S-analog values
generated shortly one after the other at the output of the
DAC are allocated
to the single axes by means of five
sample and hold circuits
-52.2-.
The five individual
analog voltages
are amplified
and buffered
subsequently
-52.3- and are led to the terminal
board.
- On the analog board the buffer
battery
(-3,46V) and the
internal
temperature
(65O) of the control
are also supervised -51-. The supervision
signals are led to the CLP
processor via the CRUIN line.
- Two "watch dog" monoflops -51.1- are on the analog board.
These must be triggered
separately
once every 5ms by the
CLP processor -4O- and once every 2Oms by the main processor
-3o-.
If the monoflops are not driven within 5ms
or 2Dms (error state),
an emergency-stop
signal is
triggered.
- The drive of the screen is another important
task of the
TNC 151 CLP processor.
It only has to write the texts to
be displayed
into the CRT RAM -41-l-.
A special CRT controller
TMS 9937 -41- generates the necessary addresses
for the CRT RAM and the character
generator
IC-P19 -41.2so that the data are transferred
to the shift register
-41.3- in the right sequence. Thus signal can be inverted
by means of an exclusive-or-gate
-41.4- to generate an
inverse video display.
The video signal,
the bright/dark

signal,
supply

the horizontal/vertical
are used to operate

sync. signals
the screen.

and an 11V

- On the SE-board (or the PLC interface


board) the V.24
signals of the handwheel unit HE 310 are connected to the
line drivers
or, respectively,
to the line receivers
-62-.
A serial
interface
module -43- on the CLP/graphic board
stands between line receivers/drivers
and the CLP processor
to transfer
data with the handwheel unit and to format data.
(start/stop
pulse e.g.)
- The signals of the 3D-probe are buffered
via the 3Dprobe-interface
on the SE-board (or the PLC interface
board) -63- and are evaluated
via the counter module
-42- on the CLP processor/graphic
board.

nellJel\nAll\
DR. JOHANNES
D-8225Traunreut

HEIDENHAIN GmbH
.Tel.(O8669)31-0

SERVICE MANUAL TNC 151


Page 54
Se&ion
4.1

Kundendienst

Power

Supply

- +5V are
converter
coupled
operation

unit

generated
for the TTL modules
via the forward
-7O-.
The flyback
regulator
-7O.linductively
with the flow converter
generates
+/-15V
for the
amplifier.

- The +12V supply


voltage
for the V.24 interface
with the help of the +15V by means of a linear

is generated
regulator

-70.2-.

- +llV are generated


via the forward
converter
-70.3for the
TNC 151 (BE 111, BE 211) screen which in contrast
to the
TNC 155 (BE 411) screen does not have an own power supply
unit.
The switch
regulator
-70.01and -70.31readjust
the
output
voltage
load controlled.
- The soft
current.

start

-71-

limits

the

relatively

high

switch-on

- On the power supply


board there
is, moreover,
a voltage
supervision
-72- triggering
a reset
signal
if the power
supply
is interrupted
or if the supply
voltage
drops below
a predetermined
minimum
level
(167V
if set for 220V
operation)
for a short
time.
If U2 (+5V) exceeds
if there
is a failure
the overvoltage
recognition
-73- is immediately
effective
and causes the
overvoltage
protection
(thyristor)
-73.1to connect
through.
Thus Ul is short-circuited
coming directly
from
the power supply
transformer
-74- via the rectifier
-75-.
A greater
damage at the subsequent
electronics
is thus
inhibited
by means of.this
protective
measure.

1 nellJelunAll\

DF

fOHANES

D 8725 Traunreut

HElDENHAlN

.Tel. (08669)

GmbH

SERVICE
Page 55
Section

31-O

Kundendienst

4.2
Block

MANUAL TNC 151


4.2
-

Block

Diagram

TNC 151

Diagram

Arrengement
PLC-I/O-Board
Paver
Supply
Terminal
Board
(P-Version)
Terminal
Board
(A-Version)
PLC Interface
Board
SE-I/O-Baord
Main Processor
Board
CLP Processor
Board
CLP Graphic
Board
Analog
Board
(TTL-1mpul6)
Analog
Board
Memory
Board
Memory
Board

Drawing
4820
4820
4820
4820
4820
4820
4820
4820
4820
4820
4820
4820
4820
4820

Nmber
EKD
EKD
EKD
EKD
EK!J
EKD
EKD
EKD
EKD
EKD
EKD
EKD
EKD
EKD

1603300
1605100
1605200
1605000
1604800
1604900
1604700
1603400
1603700
1603800
1603600
1603500
1603900
1604000

Page
56
57
58
59
60
61
62
63
64
65
66
67
68
69

Extern

Analogteil
Platine

ODER

ODER

ODER

Klemmleisten-

NetzteilPlatine
I

Stecker-

Zeichnungs-Nr.:
Iv320EK01602500

Platine

A~nordnung der Blockschaltbilder


jq

ODER

-.- .-.-_.-.-~-..~~~~
CRU -Adress
I,

-Bus

lnterfllte

I,

- Plut1nc

CRUINZ VM der 2 PLC-:

63 Eingiinge

El
Lei tungs 31 Ausgiinge
treiber
und
Stromiiberwachurq

IU Z.PLC-Em/Ausq.-Plotine
---.---

E 1.1
Auscjjnge
(Serien- 1
Parallel-C
Umsetzer) -

---~

..,.-....-.

CRUOUT. CRUCLK

1
0 PU-Interfore-PIntIne

-Ein /Ausg.-Plntme
r---.-.-.~.-~~.-y
NOT AUS van

#y
Zclchnungs
- Nr.:
G.20 E KO 1604500

(Ex ternlPLC-EinIAusgang-

Platine

75

74*
-

Netr-

trans-

N
-

Glrichrichtcr

formotor

schutz

73

2,

uv-i .
(Reset1
tflcsetl

Resetriesetiibcrwo chung

r,Ref

Stholtregler

- Nr.:

4820 E~0160f+600

1
r-

,I

70.01

l-

72

Zclrhnungs

I mit Tiefpoflfiltert

ltTLL941

ijber spannungsrrkcnnung

I
I

1
Rcf 1,

_-------

lJ3

-------

---FlunwandlerLcistungsI
scholtcr
i
I

lmit

---------

Tiefpoflfiltert

J
70.31
Stholtregler
ITL L9f.l

ex TV
Vorschub

--~-.-...

.)

Plutml

+lZV

spamungs
regk

LC Filter
Analog

/
I

r- -I.

Analog

-Sperre

CRUIN

CRUIN

CRUOUT. CAUCLK
Reset
NOT AUS

Zeichnungs

- Nr.:

LB20 E KD 1604400

zq
Klemmleisten-Platine

<

. ISV Netzted

<

ov
AnalogtellPlotine

Ausgiinge

- Bus

Referenzimpuls

E
I E
I 2

CRU -Adress

I n

- Aurgcinge

PotISctllelfel
lzur Anutogtd-

(P-Verslonl

PIIt!

ext,I

Vorschub

Schlcller
11111AnrlloqtrllPlntlml
ov

81

LC -

Sp~nMWjS-

- Ausgiinge

Analog

NOT AUS

23 x 47 n

80.1
i
NOT AUS

23 Eingiinge

i.Zeichnungs-Nr.:
~020 E K0160&200

23 Eingtinge

Schutzwiderstiinde
23x5.1

kn
80

+lSV Netrteil
Anoloqtell-

- Ausgbnge

23 Ausgiinge

Schutzwider stiinde

. --.
t
9

regler

Filter
Analog

I
+lZV

ii.l
CRU - Adress

- Bus

Referenzimpuls-Sperm

.-._.-__--_.
on HnuptrettlllerPlotine
__----_

- zu Anologteil-Platine

CRUIN 2
iRUIN

:ff

4-

(------

v---

NOT AUS -

Zrichnungr -Nr.:
4820 E KO 16Of.3 00

I-l

111111

NOT AUS
0
Analogtell
Plotinc

Blockschaltbild
PLC-Interface

TNC 1511155
-Platine

/I~-----

:-3

CRU-Adress

on HouptrechnerPlot ine

-Bus

teferenzimpuls-Sperre

- zu Anoluqteil

- Plolin~/;.-----$

NOT AUS

NOT AUS

24 Ei ngtinge

(Optokopplerl
und
Parallel /Serien
Umse tzer

24 Einghge

NOT AUS
AnoloqteilPlotine
Zcirhnunqs-

Nr.:

4820 E KO 16041 00

SE-Ein /Ausgang

- Platine

I SE IPLCurn externen Computer,


Hognetbondeinheit.
usv.
!SS- Bus
I7 bi t\

Standard

30

v. 24
RS 232(
jchni tt
stelle

-u

Haupt rechner
CPU

(16bitl-Adress-Bus

Ic

E
K-P4
IIL
I\ - Ia
II

TMS 9995
fnicht
mopbarl

8)
r!

Erweiterter

TastenfeldConh-oller

RAM
Mapper
2vx tI
(1workspa
ce
Gkm. RAt
I)

AS-Al5

K-P5
:
K-P8
?c-PI0
5x

28279-S

IErwei ter t
den AdressBus 1

PLC
RAM
4kx

8kx 8
fDDiologSpache
I
I

CRU-Daten-Bus

(Tastatur-

Platinel

II
t-u

Standard

-Nr.:

Bus

.3

zu SEIPLC-Interface-Plotine

Zeichnungs

(20bitt-Adress-

-0aten

ICRUIN.

r/i!
u

\I

- Bus
CRUOUT, CRUCLK)

zulvon Regelkr-Plot.

.q 32.1

2:

,:g;Fg .amll*
lw

Blockschaltbild

TNC1511155

Standard

(16 bit I - Adress - Bus

------I\\\

1161

7?23

Regel-

kreis -

I I2k x 8 I

77

Standard

lilf

I I II.::w7- I

t2-

- Oaten - Bus

I,.,
Zeichnungs - Nc:
4820 EKD16029 00

I-li%lI

I I I I I I

Regelkreis

- Rechner-Platine

Standard

(16 bit1 -Adress

- Bus

40
:

?egel,

I.PROt
IC-Pi

kreis,
lechne
CPU
MS 99s

----f

32k xt

- I

L-l
CRU-ootenStandard-Daten-Bus

Zeithnungs-Nr.:
LB20 EKO 16030 00

i-

I I I El I

zu Spicher> Platine

CRU-Adress-

Bus (van Regelkreis

YO Houptrerh
ner-Plotine
CRU-Adress Bus

Referenz - impulr - Sperre


1

0 SEIPU-lnkrf-Plotme

-Platine)

II

CRU-Daten-Bus

(van Regelkreis

-Platine)

cN.Blockschal tbi Id TNC1511155

Zeichnunqs - Nr.:
4820 E KD 16028 00

r-1 1 1 1
I I I I

Analogteil -PlotineITTL-Eingiinge)

CRU -Adress

-Bus

Avon Regelkreis
.ulI

-PlatineI

,,uqJ,,cr.,-

ner- Plotine
CRU-;&es
Referenz

- lmpuls

- Seerre

tOmr I Sms
lono- I Mono
flop 1 flop
I

van Houptrechner- Platine


CRU-OatenBUS

CR&&ten-Bus

Zeithnunqs - Nr.:
&820 E KO 16027 00

(van Regelkreis

-Platine

52.1

x.4
I:
Abtost,
und
HolteSchnl.
..-.
t-..,

Speicher - Adress - Bus

-< u

20
EPROM

2-

20.1

RAM

IC-PI1

(Anwender
3160 Siitze)

IC -b1e
8xBkx8

32 x 2k x 8
-

/
\
/-

Zeichnungs-Nr.:
4820 EKD1603100

CRU-Daten

- Bus

Speicher - Platine

Speicher

- Adress

- Bus

u >

20.1
RAM

EPROM
K-P11

( Anwender
1280 Siitze)

IC -bl8
16x 2kx8
-

Zeichnungs -Nr.:
4820EKD1603200

CRU-Daten

- Bus

lltllJtNllAIN
DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut Tel. (08669) 31-O

SERVICE MANUAL TNC 151


Page 70
Section
4.3

Kundendienst

4.3

Wiring

diagrams

Wiring

diagram

TNC 151 A/E

Drawing

No.

229

129

00

P.

71

Wiring

diagram

TNC 151 AR/ER

Drawing

No.

229

130

00

P.

12

Wiring

diagram

TNC 151 P/V

Drawing

No.

229

131

00

P.

73

Wiring

diagram

TNC 151 PR/VR

Drawing

No.

229

132

00

P.

74

DR. JOHANNES HEIDENHAIN GmbH


D-8225 Traunreut Tel. (08669) 31-O
Kundandienst

SERVICE MANUAL TNC 151


Paae 11
Se&ion
4.3

HEIDENHAIN
DR. JOHANNES HEIDENHAIN GmbH
D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

SERVICE

MANUAL TNC 151

Page
12
section

4.3

HEIDENHAIN
DR. JOHANNES HElDENHAlN GmbH
D-8225 Traunreut .Tel. (08669) 31-O
Kundendienst

SERVICE MANUAL TNC 151


Paae 73
Se&ion

4.3

HEIDENHAIN
DR. JOHANNES HEIDENHAlN GmbH
D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

SERVICE MANUAL TNC 151


Page 74
Section
4.3

i
1

neIuclunnllu
DR. JOHANNES HEIDENHAN GmbH
D-8225 Traunreut Tel. (08669) 31-O
Kundendienst

4.4

Machine

Parameters

SERVICE MANUAL TNC 151


Page 75
Section
4.4

neluelunnllu
DR. JOHANNES HElDENHAlN
D~8225Traunreut,Tel(O8669)
Kundendienst

GmbH
31-O

SERVICE MANUAL TNC 151


Page 76
Section
4.4

neluelurlnllu
DR. JOHANNES HEIDENHAN GmbH
D-6225 Traunreut .Tel. (08669) 31-O
Kundendienst

SERVICE MANUAL
Paws 71
Se&ion

4.4

TNC 151